introvoyz041/FactoryBench_Generation huggingface dataset:
Root cause: damaged_screw_thread
Task: screwing
Description: The screw thread itself is physically damaged, preventing proper engagement during tightening.
Severity levels: medium, high
Possible anomalies: sustained_contact_force, gradual_current_force_temperature_rise, high_current_low_motion, persistent_tracking_error, acoustic_spike_without_force
Simulation procedure: Physically damage the screw thread with a file or by cross-threading before placing it in the feeder. Run the tightening cycle and observe torque signature anomaly.
Root cause: extra_assembly_component
Task: screwing, pick_and_place
Description: An unexpected object such as a washer is present in the assembly location, altering contact geometry.
Severity levels: low, medium, high
Possible anomalies: tcp_force_spike, sustained_contact_force, persistent_tracking_error, speed_drop_with_force_spike, protective_stop_event
Simulation procedure: Place an additional washer or shim in the assembly location before the tightening cycle. The robot will detect abnormal contact geometry.
Root cause: missing_screw
Task: screwing
Description: The robot attempts tightening but no screw is present, often due to pick failure or skipped step.
Severity levels: low, medium
Possible anomalies: gripper_close_no_force, reduced_contact_force, persistent_tracking_error, unexpected_low_current_during_tightening
Simulation procedure: Remove the screw from the feeder or skip the pick step so the robot attempts to tighten an empty hole.
Root cause: damaged_plate_thread
Task: screwing
Description: The threaded hole in the plate is damaged, preventing proper screw engagement.
Severity levels: medium, high, critical
Possible anomalies: sustained_contact_force, gradual_current_force_temperature_rise, high_current_low_motion, acoustic_spike_without_force, protective_stop_event
Simulation procedure: Pre-damage the threaded plate hole with an oversized tap or by cross-threading a screw manually. Confirm thread engagement fails during the tightening cycle.
Root cause: loosening_phase
Task: screwing
Description: Robot is performing a screw loosening operation rather than tightening. This is a normal operational phase but may appear anomalous if only tightening behavior is expected.
Severity levels: none, low
Possible anomalies: reduced_contact_force, unexpected_low_current_during_tightening, persistent_tracking_error, spurious_force_spike, spurious_current_spike
Simulation procedure: Program the robot to execute a loosening (counterclockwise) rotation instead of tightening. No hardware modification required.
Root cause: motor_miscommutation
Description: Motor commutation error producing inconsistent torque-forming behaviour on an affected joint, logged as max current deviation failure.
Severity levels: medium, high
Possible anomalies: broadband_torque_noise, persistent_tracking_error, joint_current_imbalance
Simulation procedure: Power-cycle the controller; re-run a slow diagnostic cycle on the affected joint; inspect motor winding connections if the fault recurs.
Root cause: gripper_activation_failure
Task: pick_and_place
Description: The vacuum gripper fails to activate and never picks up the can. The robot completes the motion but carries no payload.
Severity levels: medium
Possible anomalies: payload_torque_absence, sustained_low_torque, torque_deviation_from_nominal
Simulation procedure: Disconnect the vacuum line or disable the solenoid valve command in the gripper control I/O, then run a pick-and-place cycle.
Root cause: gripper_release_during_motion
Task: pick_and_place
Description: The vacuum gripper releases the can mid-trajectory at a random point during transport, causing an abrupt loss of payload load on the robot arm.
Severity levels: medium
Possible anomalies: abrupt_torque_drop, oscillation_around_setpoint, sustained_low_torque, torque_deviation_from_nominal
Simulation procedure: Inject a timed solenoid OFF pulse into the gripper control line mid-trajectory via a programmable relay or script-triggered digital output.
Root cause: additional_axis_payload
Task: pick_and_place
Description: A physical weight is attached to one robot axis, increasing its effective inertia and gravity loading. Affects torque demands on all joints due to the kinematic chain.
Severity levels: low, medium, high
Possible anomalies: torque_sensor_elevation, increased_computed_inertia, motor_iq_elevation, persistent_tracking_error
Primary error code: C153A0
Related error codes: C153A0, C153A1, C153A2, C153A3, C153A4, C153A5, C173A0, C173A1, C173A2, C173A3, C173A4, C173A5
Simulation procedure: Attach a calibrated dead weight (e.g. 0.5-2 kg) directly to one of the robot links using a mechanical fixture, then run the standard program.
Root cause: collision_foam_object
Task: pick_and_place
Description: The robot contacts a soft foam block placed in the workspace. The low stiffness of foam absorbs most of the impact energy, producing a brief TCP force spike and transient torque perturbation without triggering a protective stop.
Severity levels: low
Possible anomalies: tcp_force_spike, oscillation_around_setpoint
Primary error code: C157A
Related error codes: C157A
Simulation procedure: Place a foam cube or foam block directly in the programmed trajectory of the TCP. The robot will push through or deflect it with only a brief force spike recorded.
Root cause: cable_routed_on_robot
Description: A cable or tether is routed along the robot arm, adding asymmetric drag and torque bias on one or more joints throughout motion.
Severity levels: low, medium
Possible anomalies: persistent_tracking_error, sustained_contact_force, oscillation_around_setpoint
Simulation procedure: Reroute the cable off the robot link or add a service loop; run a test cycle and verify joint torques return to nominal.
Root cause: invalid_gripping_position
Description: The can is gripped at an unusual or offset position due to a timing error in the pick sequence, causing an asymmetric payload distribution and altered gripper-to-can contact geometry.
Severity levels: low, medium
Possible anomalies: persistent_tracking_error, tcp_force_spike, speed_drop_with_force_spike
Simulation procedure: Introduce a software time delay (e.g. a sleep() call) in the URScript before the gripper activation command, so the gripper closes after the arm has already begun its lift motion, causing it to grip the can at an off-center or tilted position.
Root cause: unstable_mounting_platform
Task: pick_and_place
Description: The robot's mounting platform is unstable due to released wheel brakes or uneven foam placement beneath it, introducing low-frequency vibrations into the arm during motion. Conceptually related to fixture_instability (fault_id 11) but applies to the robot base rather than the workpiece.
Severity levels: low, medium, high
Possible anomalies: broadband_torque_noise, oscillation_around_setpoint, joint_current_imbalance
Primary error code: C173A0
Related error codes: C157A, C173A0, C173A1, C173A2, C173A3, C173A4, C173A5
Simulation procedure: Release the wheel brakes of the robot trolley, or place calibrated foam pads of varying thickness under the base mounting plate.
Root cause: gearbox_overload
Description: A joint gearbox is loaded beyond its rated torque, producing elevated current draw and eventual stall or protective stop.
Severity levels: medium, high, critical
Possible anomalies: high_current_low_motion, gradual_current_force_temperature_rise, protective_stop_event
Simulation procedure: Stop the program; reduce payload or trajectory aggressiveness; inspect the gearbox for damage before resuming.
Root cause: joint_position_limit_violation
Description: Robot joint moved outside its configured soft or hard position limits, triggering a safety stop.
Severity levels: medium, high
Possible anomalies: protective_stop_event, persistent_tracking_error
Primary error code: C39A3
Related error codes: C1A
Simulation procedure: Program a waypoint slightly beyond the configured soft joint limit and execute the move, or manually shift a joint limit in the safety configuration to encroach on the normal trajectory.
Root cause: tcp_frame_misconfiguration
Description: The Tool Center Point (TCP) frame or mounting orientation is configured incorrectly in PolyScope, causing the robot to detect unexpected gravitational torques consistent with wrong mounting.
Severity levels: low, medium
Possible anomalies: protective_stop_event, persistent_tracking_error
Primary error code: C156A
Related error codes: C156A, C155A
Simulation procedure: Enter an incorrect TCP offset (e.g. shift X by 100 mm) or wrong mounting angle in the Installation > TCP configuration in PolyScope, then run the program.
Root cause: payload_misconfiguration
Description: The payload mass is left at 0 kg in the robot configuration while a tool or workpiece is physically attached, causing the collision detection model to trigger on normal inertial forces.
Severity levels: low, medium
Possible anomalies: protective_stop_event, speed_drop_with_force_spike
Primary error code: C158A
Related error codes: C158A, C162A
Simulation procedure: Ensure the installation payload is set to 0 kg while a tool (e.g. gripper, 300 g) is physically mounted, then run a standard pick-and-place cycle.
Root cause: external_arm_disturbance
Description: An external force continuously pulls or pushes the robot arm during motion, such as a tethered cable, hanging weight, or operator interference, causing persistent torque anomalies.
Severity levels: low, medium, high
Possible anomalies: tcp_force_spike, sustained_contact_force, protective_stop_event
Primary error code: C111A
Related error codes: C111A
Simulation procedure: Anchor a spring or elastic band between a fixed point in the workspace (e.g. the bench frame) and the robot tool flange, with no contact along the arm links. Run the standard trajectory so the arm experiences a continuously varying external pull force at the TCP only. Alternatively, have an operator apply a steady manual push/pull force on the tool flange during motion.
Root cause: payload_cog_misconfiguration
Description: The payload center of gravity (CoG) is specified at an incorrect offset from the tool flange, causing the gravity compensation model to apply wrong torques and triggering protective stops during motion.
Severity levels: low, medium
Possible anomalies: protective_stop_event, persistent_tracking_error
Primary error code: C162A
Related error codes: C162A, C156A
Simulation procedure: Set the center of gravity offset in the payload configuration to a position far from the actual tool CoG (e.g. 150 mm offset in Z), then execute a multi-pose trajectory.
Root cause: collision_hanging_cable
Task: pick_and_place
Description: A cable or wire hangs across the robot workspace and contacts the arm or tool during motion. The flexible cable wraps around or drags along the arm, producing a sustained asymmetric pull force and persistent torque anomaly rather than a sharp impact.
Severity levels: low, medium
Possible anomalies: sustained_contact_force, persistent_tracking_error, oscillation_around_setpoint
Primary error code: C157A
Related error codes: C157A, C111A
Simulation procedure: Suspend a loose cable or wire across the robot trajectory at arm height so it drags along the robot link or tool flange during the motion cycle.
Root cause: collision_cardboard_object
Task: pick_and_place
Description: The robot strikes a cardboard carton or flat-pack box placed in its path. Cardboard provides moderate resistance — the robot may displace the object or, if the carton is braced, generate enough torque deviation to trigger a protective stop.
Severity levels: low, medium
Possible anomalies: tcp_force_spike, speed_drop_with_force_spike, protective_stop_event
Primary error code: C157A
Related error codes: C157A, C283A26
Simulation procedure: Place a cardboard box (free-standing or lightly braced) in the robot trajectory. A free box will be pushed, recording a moderate spike; brace the box against a wall to increase resistance and provoke a protective stop.
Root cause: collision_rigid_object
Task: pick_and_place
Description: The robot collides with a hard, immovable object such as a metal fixture, tool stand, or structural element. The high contact stiffness produces an immediate large torque deviation and invariably triggers a protective stop.
Severity levels: medium, high
Possible anomalies: tcp_force_spike, protective_stop_event
Primary error code: C157A
Related error codes: C157A, C158A
Simulation procedure: Place a rigid metal block or clamp a solid fixture at a position that intersects the programmed TCP path. Run the program at normal speed; the collision will trigger an immediate protective stop.
Root cause: peg_insertion_misalignment
Task: machine_tending
Description: The peg approaches the hole at an angular or lateral offset, causing the tip to jam against the hole rim rather than enter cleanly, producing elevated contact forces and position tracking errors.
Severity levels: low, medium
Possible anomalies: tcp_force_spike, persistent_tracking_error, protective_stop_event
Simulation procedure: Introduce a small angular offset (e.g. 2-5 degrees) or lateral offset (e.g. 3-8 mm) in the insertion approach waypoint in the robot program, so the peg contacts the hole rim instead of entering cleanly.
Root cause: hole_obstruction
Task: machine_tending
Description: A foreign object or debris is lodged inside the insertion hole, preventing full peg insertion and generating an abnormal force buildup as the peg contacts the obstruction.
Severity levels: medium, high
Possible anomalies: sustained_contact_force, tcp_force_spike, protective_stop_event
Simulation procedure: Place a small object (e.g. a metal chip, rubber disc, or folded paper) inside the hole before the insertion cycle. The peg will contact the obstruction mid-insertion, producing a distinct force anomaly.
Root cause: incorrect_insertion_depth
Task: machine_tending
Description: The insertion motion terminates at an incorrect Z depth due to a misconfigured waypoint, leaving the peg partially inserted (too shallow) or causing it to over-push against the hole bottom (too deep).
Severity levels: low, medium
Possible anomalies: persistent_tracking_error, sustained_contact_force
Simulation procedure: Modify the insertion endpoint waypoint Z offset in the robot program by +/- 10-20 mm from the nominal value. Too shallow leaves the peg proud; too deep drives it against the fixture bottom.
Root cause: peg_surface_contamination
Task: machine_tending
Description: Contamination or increased surface roughness on the peg (e.g. chalk, adhesive residue, or grit) raises insertion friction, producing stick-slip force patterns and higher-than-nominal contact force throughout the insertion stroke.
Severity levels: low, medium
Possible anomalies: sustained_contact_force, speed_drop_with_force_spike
Simulation procedure: Apply a thin layer of dry chalk powder, fine abrasive paste, or low-tack adhesive to the peg surface before the insertion cycle to increase surface friction.
Root cause: fixture_displacement
Task: machine_tending
Description: The insertion fixture has shifted laterally from its nominal position due to vibration, impact, or improper clamping, creating a positional mismatch between the programmed approach and the actual hole location.
Severity levels: low, medium, high
Possible anomalies: tcp_force_spike, persistent_tracking_error, protective_stop_event
Simulation procedure: Deliberately shift the hole fixture by a controlled lateral offset (e.g. 5-15 mm) from its nominal position without updating the robot program waypoints.
Root cause: self_collision_link_interference
Description: The robot trajectory passes through a configuration where an arm link collides with the robot's own body or mounting fixture, triggering an immediate protective stop.
Severity levels: medium, high
Possible anomalies: tcp_force_spike, protective_stop_event, persistent_tracking_error
Primary error code: C157A
Related error codes: C157A, C158A
Simulation procedure: Program a waypoint that requires the arm to fold into a self-colliding configuration, or deliberately offset the mounting fixture so the standard trajectory causes a link to contact it.
Root cause: missing_box
Task: pick_and_place
Description: The robot executes the full pick-and-place cycle but no box is present at the pick position. The gripper closes on empty air and the arm transports no payload, producing a torque and current profile consistent with an unloaded trajectory.
Severity levels: low, medium
Possible anomalies: payload_torque_absence, sustained_low_torque, gripper_close_no_force, torque_deviation_from_nominal
Simulation procedure: Remove the box from the pick position before the episode starts. The robot runs the standard pick-and-place program unmodified.
Root cause: missing_peg
Task: peg_in_hole
Description: The robot executes the full peg-in-hole cycle but no peg is gripped. The arm descends into the hole empty-handed and the insertion phase produces no contact force, resulting in an anomalously low force and torque profile during what should be a high-contact phase.
Severity levels: low, medium
Possible anomalies: reduced_contact_force, gripper_close_no_force, sustained_low_torque, torque_deviation_from_nominal
Simulation procedure: Remove the peg from the gripper or skip the peg pick-up step before the episode starts. The robot runs the standard insertion program unmodified.